JOTTER NOTES

Name: Pugallan A/L Nadarajah

Date: 28/3/2016

ID No: 55213114377

Experiment No. and Title: Experiment 1 [Air Pressure Process Control (AP 922)]

Objectives:

1. To identify the important components of the air pressure control system and to mark them
in the P&I Diagram.
1. To carry out the start-up procedures systematically.
2. To control the pressure in single capacity and two capacity processes using PID
Controller.

Start-Up Procedures:

The following steps constitute the start-up procedures. Go through these steps before starting any
experiment.

Turn the "PANEL, SCADA/DDC" selector switch at the front of the cubicle to the "PANEL, SCADA"
position. Switch ON the main power supply at the front of the cubicle. All the panel instruments will lit
up.

If the recorder chart drive is running, STOP it by pressing the 'RCD' pushbutton. If any annunciator gets
activated, press the ACKNOWLEDGE button to silence the buzzer.

Set the instrument air supply (IAS) regulator to the pressure indicated at the air regulators (this is the air
supply to the pneumatic control valves PCV91 and PCV92). Purge if there is any condensed water in
the air regulators by opening the bottom drain valves.

Make sure that the by-pass valves around the control valves PCV91 and PCV92 are shut fully and the
pair of manual valves on the upstream and downstream lines of these control valves is opened.

Check that the control valve positioner (PP) of PCV91 is connected (ON) (i.e. not by-passed).

Make sure the compressed air is available at the pressure inlet air regulator, AR91 by setting the AR91
to the indicated pressure.
 Check that the vent valve (V) and bottom drain valve (D) of vessel T9I1are shut.

SHUT fully the manual valves MV91B and MVIII. SHUT fully the process inlet manual valve MV91.

Place the panel controller PIC91 in Manual (M) mode and adjust its MV = - 6.3% to open the control
valve PCV9I fully.

Open fully the final discharge manual valve (VP). This valve is at downstream of pressure control
valve PCV91.

From the process air supply, trace the two pipe lines PLI and PLII as follows:

Pipeline I (PLI):
Single capacity process:
AR91-MV91-T91-PLI-B92-FI92-PCV91-VP
Two-capacity process
AR91-MV91-T91-PLI-MVI-T92-MV92-FI92-PCV91-VP
Pipeline II (PLII):
AR91-MV9I-T9I-PLII-MVII-PCV92-MV92A/MV92B-V

Open fully the pipeline PLI (Single capacity process) and PLII at their various manual valves.

Make sure the manual by-pass valve B92 around vessel T92 is opened and the manual valves at
the inlet MVI and outlet MV92 of T92 are shut.

The pipeline PLII has two discharge manual valves, MV92A (globe valve) and MV92B (gate
valve). SHUT both valves MV92A and MV92B.

Check and adjust the pressure at AR91 is approximately at the pressure indicated at AR91.
Check MV91 is fully shut.

Slowly open MV91 and regulate it until the flow rate at the variable area flow meter FI92 reads 35
Nm3/hr.

Check the pressure and flow rate setting:

a. Shut fully PCV91 from PIC91 in manual (M) mode with by adjusting MV=106.3%. Read
the pressure at vessel T91 at the PV reading of PIC91. If the pressure is about 22 to 27 psig,
the pressure is correctly set.
b. Open fully PCV91 from PIC91 in manual (M) mode with MV= -6.3%. Read the pressure
at vessel T91 at the PV reading of PIC91. If the pressure is not more than 6 psig and the
flow rate at FI92 also reads 35 Nm3/hr, the air flow rate is correctly set.
c. Now the process air supply pressure and flow rate are set. DO NOT readjust AR91 and
MV91 hereafter.
PID CONTROL OF PRESSURE IN SINGLE CAPACITY PROCESS (T91)

Make sure that you have gone through the START-UP procedures very carefully.

Start the chart drive of the recorder by pressing the 'RCD’ pushbutton at the front of the recorder
PR91. Make sure that pipelines PLI and PLII are opened throughout.

Open only the manual discharge globe valve MV92A at the common vent of PLII. Close the gate
valve MV92B at the common outlet of PLII.

For single capacity operation, only vessel T91 is used. Vessel T92 is by-passed.
A) Open by-pass valve B92 around T92.
B) Shut the manual valves at the inlet, MVI and at the outlet, MV92, of T92.
C) Make sure the air flow path T91-PLI-FI92-PCV91-VP is opened through B92.

Set the set point of the air pressure for this process at PIC91 as SV = 15 psig.

Set the PID controller with the first (I) trial values:
PB1 = 70%, T11 = 40 s, TD1 = 0 s

Transfer the controller to Auto (A) mode and wait for the process response to become almost stable.

DO NOT FORGET TO MARK THE PID VALUES AND THE SET-POINT ON THE CHART
PAPER WHENEVER THE V ALUES ARE CHANGED. ALSO MARK ON THE CHART
THE BEGINNING OF EACH PART OF THE EXPERIMENT.

Switch PIC91 to Manual (M) mode, decrease MV by about (5 to 10) % [do not change the MV to the
5 or 10% value], bring back PIC91 to Auto (A) mode and observe the response for a few minutes.

If the response is slow to return to the set point, SV = 15 psig, reduce TI1 value to 20 s and repeat step
(10) again.

Now set the PID controller with the second (II) trial values:
PB1= 45%, TI1 = 30 s, TD1 = 0 s

Switch PIC91 to Manual (M) mode, decrease MV by about (5 to 10) % [do not change the MV to 5 or
10% value], bring back to Auto (A) mode and observe the response for a few minutes.

If the response is not oscillatory, proceed with the next step. If the response is oscillatory, increase PB1
value to 50% and repeat step (15).
Try the third (III) trial values for the PID controller:
PB1 = 20%, TI1 = 10 s, TD1 = 2 s

Introduce the disturbance in MV as in step (13) and observe the response.

STOP the chart drive and retrieve the relevant portions of the chart paper. Attach the chart paper along
with the results.

PID CONTROL OF PRESSURE IN TWO CAPACITY PROCESS (T91 & T92)

Make sure that pipelines PLI and PLII are opened throughout. Open only the manual discharge globe
valve MV92A at the common vent of PLII.

Mark the MV value at pH=7. Change MV by 10-20%. Note the new MV and step change in MV.

Close the gate valve MV92B at the common outlet of PLII.

For two- capacity operation, vessels T91 and T92 are used.
A) Shut the by-pass valve B92 around T92
B) Open the manual valves at the inlet, MVI, and at the outlet, MV92, of T92.
C) Make sure the air flow path T91-PLI-T92-FI92-PCV91-VP is opened through MVI and MV92.

Start the chart drive of the recorder by pressing the 'RCD' pushbutton at the front of the recorder
PIC91.

Switch PIC91 to Manual (M) mode.

Open control valve PCV91 about 50% from PIC91 by adjusting MV = 50%.

Set the set point of the air pressure for this process PIC91 as SV = 18 psig.

Set the PID controller with the first (I) trial values:
PB1 = 70%, T11 = 40 s, TD1 = 0 s

Transfer the controller to Auto (A) mode and wait for the process response to become almost stable or
continue to oscillate.

DO NOT FORGET TO MARK THE PID VALUES AND THE SET-POINT ON THE CHART
PAPER WHENEVER THE V ALUES ARE CHANGED. ALSO MARK ON THE CHART
THE BEGINNING OF EACH PART OF THE EXPERIMENT.
Switch PIC91 to Manual (M) mode, bring MV to 40%, switch back PIC91 to Auto (A) mode and
observe the response until it becomes steady or continue to oscillate even after 3 cycles.

If the response is slow to return to the set point, SV = 18 psig, reduce TI1 value to 20 s and repeat
step (11) again.

Now set the PID controller with the second (II) trial values:
PB1= 45%, TI1 = 30 s, TD1 = 0 s

Switch PIC91 to Manual (M) mode, decrease MV by about (5 to 10) % [do not change the
MV to 5 or 10% value], bring back to Auto (A) mode and observe the response for a few minutes.

If the response is not oscillatory, proceed with the next step. If the response is oscillatory, increase
PB1 value to 50% and repeat step (14).

Try the third (III) trial values for the PID controller:
PB1 = 20%, TI1 = 10 s, TD1 = 2 s

Introduce the disturbance in MV as in step (14) and observe the response until it becomes steady.

STOP the chart drive and retrieve the relevant portions of the chart paper. Attach the chart paper along
with the results.

SHUT DOWN PROCEDURES

Stop the recorder chart drive by pressing the 'RCD' button at the front of the recorder. Turn off the
recorder PR91. Switch the controller PIC91 to Manual (M) mode with its control output MV= 0%.

Switch OFF the main power supply.

SHUT the process air supply regulator AR91 and process air supply manual valve MV91.

SHUT the instrument air supply.

Parameter (s) Studied in the experiment:

a) Level-flow control system

b) Level measurement.
c) PID level control.
d) PID tuning.
e) PH-Neutralization.